RK-04 M2 Transmitter Operator s Manual

Transcription

1 RK-04 M2 Transmitter Operator s Manual Part Number: RK Revision: 0 Released: 12/27/13 RKI Instruments, Inc.

2 WARNING Read and understand this instruction manual before operating instrument. Improper use of the gas monitor could result in bodily harm or death. Periodic calibration and maintenance of the gas monitor is essential for proper operation and correct readings. Please calibrate and maintain this instrument regularly! Frequency of calibration depends upon the type of use you have and the sensor types. Typical calibration frequencies for most applications are between 3 and 6 months, but can be required more often or less often based on your usage RK-04 M2 Transmitter Operator s Manual

3 Product Warranty RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in materials, workmanship, and performance for a period of one year from date of shipment from RKI Instruments, Inc. Any parts found defective within that period will be repaired or replaced, at our option, free of charge. This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal service, and which must be cleaned, repaired, or replaced on a routine basis. Examples of such items are: a) Absorbent cartridges d) Batteries b) Pump diaphragms and valves e) Filter elements c) Fuses Warranty is voided by abuse including mechanical damage, alteration, rough handling, or repair procedures not in accordance with the operator s manual. This warranty indicates the full extent of our liability, and we are not responsible for removal or replacement costs, local repair costs, transportation costs, or contingent expenses incurred without our prior approval. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF RKI INSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY. This warranty covers instruments and parts sold to users by authorized distributors, dealers, and representatives as appointed by RKI Instruments, Inc. We do not assume indemnification for any accident or damage caused by the operation of this gas monitor, and our warranty is limited to the replacement of parts or our complete goods RK-04 M2 Transmitter Operator s Manual

4 Table of Contents Chapter 1: Introduction Overview About the M2 Transmitter About this Manual Specifications Chapter 2: Description Overview External Description Internal Description Chapter 3: Installation & Startup Overview Mounting the M2 Transmitter Wiring the M2 Transmitter Start Up Chapter 4: Operation Overview Normal Operation Information Screen ma Signal Output Operation Alarm Indications Chapter 5: Configuration Mode Overview Viewing & Changing M2 Parameters Chapter 6: Gas Type Mode Overview Selecting the Gas Type RK-04 M2 Transmitter Operator s Manual

5 Chapter 7: Maintenance Overview Preventive Maintenance Troubleshooting Calibration Frequency Calibration Replacing the Combustible Gas Detector Chapter 8: RS-485 Modbus Output Overview Wiring the M2 in a Modbus System Using the M2 in a 4-wire Modbus System Modbus Mode Supported Modbus Functions Parts List Appendix A: Control Button Quick Reference Guide Appendix B: PLC and DCS Device Wiring Appendix C: Function Code 16 Registers (Appendix C available from RKI Instruments, Inc. Not included in manual as normally provided with M2 detector head.) RK-04 M2 Transmitter Operator s Manual

6 Chapter 1: Introduction Overview This chapter briefly describes the RK-04 M2 Transmitter. This chapter also describes the RK-04 M2 Transmitter Operator s Manual (this document). Table 1 at the end of this chapter lists the specifications for the M2. About the M2 Transmitter About this Manual The M2 transmitter is a fixed mount, continuous-monitoring detector head. All user adjustable parameters may be accessed using push button switches. In addition, calibration may be performed non-intrusively by use of a magnetic wand accessory which activates magnetic switches through a window at the front face of the detector head. The M2 displays the current gas reading on an LCD display which is visible through the window in the cover (front face) and provides a 4-20 ma signal which indicates the target gas reading for use by a gas monitoring controller, recording device, or programmable controller. The M2 also provides an RS-485 Modbus output. Three sets of relay contacts, two controlled by the gas alarms and one by the fail alarm, rated at 115 VAC 5 amps are available for controlling devices such as lights or horns or for controlling higher rated relays. Four operating modes allow you to display and change setup and calibration settings and change the gas type. They are Calibration Mode, Configuration Mode, Gas Type Mode, and Modbus Mode. The M2 Transmitter Operator s Manual uses the following conventions for notes, cautions, and warnings. NOTE: Describes additional or critical information. CAUTION: Describes potential damage to equipment. WARNING: Describes potential danger that can result in injury or death RK-04 M2 Transmitter Operator s Manual

7 Specifications Table 1 lists specifications for the M2. Table 1: M2 Specifications Target Gas/Detection Range Alarm Settings (Alarm 1/Alarm 2) Combustible Gas (methane calibration standard): 0-100% LEL, 1% LEL increments 10 %LEL/50 %LEL Construction (housing) Explosion-proof Junction Box, NEMA 4 Area Classification Sampling Method Input Power Explosion-proof for Class I, Groups B, C, and D Diffusion VDC Controls Three push button switches Three magnetic switches for non-intrusive calibration Weight 5.5 lbs. Signal Output 4 to 20 ma, 500 ohms impedance max RS-485 Modbus Operating Temperature -20 C to 50 C Accuracy ± 5% of reading or ± 2% LEL (whichever is greater) * These are the RKI factory settings. You can change the alarm settings in Configuration Mode. See Viewing & Changing M2 Parameters on page 22. WARNING: When using the M2, you must follow the instructions and warnings in this manual to assure proper and safe operation of the M2 and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the M2 as described in this manual. WARNING: M2 detector heads with firmware version 5.0 or later have a different Modbus register assignment than M2s with previous versions of firmware. If you are adding M2s with firmware version 5.0 or later to an existing Modbus network installation, confirm what firmware version is installed in the M2s already in the network and if necessary, take all steps required to address the differences in Modbus register assignments. See Supported Modbus Functions on page 41 for information on the current Modbus register assignments. The firmware version is shown on the Information Screen described on page RK-04 M2 Transmitter Operator s Manual 2

8 Chapter 2: Description Overview External Description This chapter describes the components of the M2 transmitter. The transmitter is a 4-20 ma type detector head. It consists of the combustible gas detector, calibration adapter/ splash guard, terminal PCB, the M2 junction box, and the detector junction box. The two junction box configuration is intended for situations where the detector needs to be installed at an inaccessible location. The detector junction box can be installed at the inaccessible location and the M2 junction box can be installed in a more readily accessible area. This section describes the junction boxes and all external components of the M2 transmitter. 3/4" NPT Conduit Hub Mounting Slot (2x) Terminal Strip Magnetic Wand Window M2 Junction Box 3/4" NPT Conduit Hub Detector Junction Box Combustible Gas Detector Calibration Adapter/ Splash Guard Figure 1: M2 External Components RK-04 M2 Transmitter Operator s Manual

9 M2 Junction Box The M2 s cast aluminum junction box protects the terminal PCB and wiring connections made to the terminal PCB. Use the top 3/4 conduit hub to connect wiring from the terminal PCB to external power and/or to an external device, typically an RKI controller. Use the bottom 3/4 conduit hub to wire the remotely installed combustible gas detector. Use the junction box s two mounting slots to mount the M2 to a vertical surface at the monitoring site. The window in the cover on the front of the junction box allows you to view the LCD display and use the magnetic wand to actuate the magnetic control switches so you can perform non-intrusive calibration. Removing the cover allows you to access the interior of the junction box. Detector Junction Box The detector junction box is intended to be installed remotely from the M2 junction box. The combustible gas detector is factory installed in the bottom 3/4 NPT conduit hub using a 3/4 in. x 1/2 in. NPT reducer. A terminal strip is provided for wiring connections and the detector is factory wired to one side of this terminal strip. The other side of the terminal strip is for user-supplied wiring to the detector terminal strip located in the M2 junction box. This wiring should go through the top 3/4 conduit hub. Three spacers installed on the back of the junction box controls the distance of the junction box from a mounting surface. Combustible Gas Detector The combustible gas detector is a catalytic type detector that produces an electrical output that corresponds to the detection range. It is packaged in a 1/2 inch NPT nipple with a sintered metal flame arrestor on one end allowing ambient air to diffuse into the detector. The flame arrestor also contains any sparks which may occur within the detector. The 1/2 inch NPT mounting threads at the top of the detector allow you to mount it into the bottom conduit hub of the junction box. The junction box conduit hub is 3/4 NPT, so a 3/4 in. x 1/2 in. NPT reducer is used to install the combustible gas detector. A rainshield screws onto the bottom of the detector (flame arrestor end). The rainshield helps protect the detector from rain and debris in the monitoring environment. Four color-coded leads extend from the top of the detector. The leads allow you to connect the detector to the terminal strip. Calibration Adapter/Splash Guard A calibration adapter/splash guard is installed on the combustible gas detector. A fitting at the bottom of the calibration adapter/splash guard allows a length of tubing to be connected for calibration and routed to a more easily accessible location (near the M2 junction box is optimal for ease of calibration). The calibration adapter/splash guard also protects the detector from splashing water or direct water spray. Magnetic Wand The magnetic wand is a short plastic rod with a magnet in one end. It is used to actuate the magnetic control switches on the control PCB while the junction box cover is still installed so that non-intrusive calibration can be performed RK-04 M2 Transmitter Operator s Manual 4

10 Internal Description This section describes the internal components of the M2. The internal components of the M2 include the terminal PCB which provides for all the wiring connections to the M2 and the control PCB which displays the gas reading and has the control buttons. 3/4" NPT Conduit Opening for Wire Entry Power/Signal Terminal Strip Detector Terminal Strip Detector Current Pot (Factory Adjust) LEL PWR/SIG - S + R W G B - S + PWR/SIG R W G B LEL C NC NO FAIL C NC NO ALARM 1 Relay Terminal Strips Junction Box Terminal PCB Control PCB Magnetic Switches UP/YES DOWN/NO ENTER RKI INSTRUMENTS Fail LED Alarm 1 LED Alarm 2 LED RX LED TX LED R S 485 A B C A B C RS 485 C NC NO ALARM 2 M2 TRANSMITTER Programming Connector (Factory Use) Modbus Terminal Strip Termination Jumper Display Ribbon Cable Connector 3/4" NPT Conduit Opening for Detector J-Box Wiring Push Button Control Switches UP/YES DOWN/NO ENTER LCD Display View With Cover and Control PCB Removed View With Cover Removed Terminal PCB Figure 2: M2 Internal Components The terminal PCB is encapsulated in epoxy for protection against moisture and physical damage. It is mounted into the rear of the junction box with three standoffs and rests on a thin layer of foam. A banana jack is screwed into each of the standoffs and used for mounting the control PCB. The terminal PCB converts the electrical output from the detector to a signal which can be displayed by the LCD display, a 4-20 ma signal (that is proportional to the detection range), and an RS-485 Modbus output signal. The 4-20 ma signal may be used by a recording device, gas monitor controller, or programmable controller. The Modbus output may be used to connect the M2 to a Modbus network. The terminal PCB also controls three relays, one fail and two gas alarm relays. Two columns of plug-in style terminal strips are used to make all wiring connections to the M2. The column on the left consists of the power/signal, detector, and Modbus terminal strips. The column on the right consists of the relay terminal strips. A 20 position connector at the bottom of the terminal PCB is used to connect the terminal PCB to the RK-04 M2 Transmitter Operator s Manual

11 control PCB with a ribbon cable. A 5 position connector on the left side of the terminal PCB is used by factory or field service personnel to program the M2. A factory adjust pot just above the programming connector is used to set the detector current. Power/Signal Terminal Strip The power/signal terminal strip is a three position plug-in style terminal strip located at the top of the left terminal column. It is used to connect 24 VDC power to the M2 and to connect the 4-20 ma output signal to a device. The signal output, the S terminal, does not have to be connected for the M2 to function. The S terminal is used if you want to connect the 4-20 ma output signal to another device such as a gas monitoring controller, chart recorder, or programmable controller (PLC). Detector Terminal Strip The detector terminal strip is a four position plug-in style terminal strip and is the middle terminal strip in the left terminal column. All four terminals are used to connect the detector to the M2. Detector Terminal Strip - S + PWR/SIG RS 485 A B C C NC NO FAIL A B C RS 485 C NC NO ALARM 2 LEL R W G B PWR/SIG - S + R W G B LEL C NC NO ALARM 1 Figure 3: Detector Terminal Strip NOTE: The detector is factory-wired to the M2. See Wiring the M2 Transmitter on page 11 for all wiring procedures related to M2. Modbus Terminal Strip The Modbus terminal strip is a three position plug-in style terminal strip and is the bottom terminal strip in the left terminal column. It allows connection of the M2 into a Modbus network. Relay Terminal Strips The right column of terminal strips consists of, from top to bottom, the fail, alarm 1, and alarm 2 relay terminal strips. They are three-position plug-in style terminal strips. The relay terminal strips are used to connect devices such as lights and horns that are controlled by the relay contacts. The relay contacts are rated at 115 VAC, 5 amps. The relay contacts may also be used to control higher rated relays RK-04 M2 Transmitter Operator s Manual 6

12 Termination Jumper A two pin header with a termination jumper installed is located below the Modbus terminal strip. The jumper has no function unless the M2 is wired into a Modbus installation. See Chapter 8: RS-485 Modbus Output on page 36 for a description of using the M2 in a Modbus system. Control PCB The LCD display and control switches are located on the control PCB. It is installed on top of the terminal PCB by lining up its three spacing standoffs with the banana jacks in the terminal PCB mounting standoffs and pushing it onto the banana jacks. The jacks retain the control PCB. LCD Display The LCD display is located at the top of the control PCB. It indicates the current gas reading and displays messages and parameters in the M2 s programs. Control Buttons The M2 includes three push button switches that allow you to enter the M2 s operating modes, navigate through the modes, update settings, and save changes to the settings. The push button switches are located along the bottom edge of the control PCB (see Figure 2). The UP/YES button is on the left, the DOWN/NO button is in the middle, and the ENTER button is on the right. Table 2: M2 Control Button Functions Switch Function UP (YES) Saves settings Changes the displayed setting Enters the Calibration Program Enters Gas Type Mode (press with DOWN/NO button) Enters Configuration Mode (press with ENTER button) DOWN (NO) Cancels setting changes Changes the displayed setting Enters Gas Type Mode (press with UP/YES button) Enters Modbus Mode (press with ENTER button) Displays the Information Screen ENTER Initiates operations Enters Configuration Mode (press with UP/YES button) Enters Modbus Mode (press with DOWN/NO button) Functions as an alarm reset switch Just above each push button switch is a magnetic switch with the same function as the push button switch below it. The magnetic switches are for use in non-intrusive calibration. They are actuated by bringing the magnetic wand close enough to them to actuate them. Although the magnetic switches have the same functions as the push button switches, it is not practical to use them for operations other than calibration because it is not possible to actuate two magnetic switches at once with only one magnetic wand. Since displaying the Information Screen only requires the use of one switch, the wand may be used to show the Information Screen (see Information Screen on page 17) RK-04 M2 Transmitter Operator s Manual

13 Status LEDs The M2 includes five status LEDs that are located above the display (see Figure 2). Fail LED The fail LED turns on when the M2 is experiencing a fail condition. A fail condition can be caused by a detector failure or low detector signal. Alarm 1 LED The alarm 1 LED is on when the M2 is experiencing an alarm 1 condition. Alarm 2 LED The alarm 2 LED is on when the M2 is experiencing an alarm 2 condition. RX & TX LED s These LED s indicate data being received (RX) and transmitted (TX) when the M2 s Modbus output is operating RK-04 M2 Transmitter Operator s Manual 8

14 Chapter 3: Installation & Startup Overview This chapter describes procedures to mount the M2 Transmitter in the monitoring environment and wire it to input power and devices. Mounting the M2 Transmitter 1. Select a mounting site that is representative of the monitoring environment. Consider the following when you select the mounting site. For the M2 junction box, select a site where the junction box is not likely to be bumped or disturbed. Make sure there is sufficient room to perform start-up, maintenance, and calibration procedures. The site should be easily accessible. For the detector junction box, select a site where the target gas is likely to be found first. For lighter gases, mount the detector near the ceiling; for heavier gases, mount the detector near the floor. The junction boxes should be mounted no further than 200 feet from each other. 2. Use #10 screws through the M2 junction box s two mounting slots to secure the junction box to a vertical surface. Figure 4 shows the outline and mounting dimensions the M2 junction box. Figure 5 shows the outline and mounting dimensions for the detector junction box. Mount the detector junction box with the detector facing down as shown in Figure /4 NPT 2.41 Conduit Hub (2X).47 (2X) Figure 4: Outline & Mounting Dimensions, M2 Junction Box RK-04 M2 Transmitter Operator s Manual

15 3/4 Conduit Hub Ø Rubber Spacer, 3X Max Combustible Gas Detector Calibration Adapter/ Splash Guard 1.13 Figure 5: Outline & Mounting Dimensions, Detector Junction Box 3. Install 3/16 inch I.D. flexible polyurethane tubing to the fitting at the bottom of the calibration adapter/splash guard and route it to an accessible area that is close to the M2 junction box. See the Parts List on page 46 for available tubing RK-04 M2 Transmitter Operator s Manual 10

16 Wiring the M2 Transmitter WARNING: Always verify that the power to the M2 is off before you make wiring connections. 1. Confirm that no power is being applied to the M2. 2. Remove the detector junction box s cover from the junction box. 3. Remove the M2 junction box s cover from the junction box. 4. Grasp the control PCB by its edges. 5. Gently pull until the control PCB is pulled away from the banana jacks. Take care not to pull too hard and damage the cable which connects the control and terminal PCBs. 6. Let the control PCB hang by the cable. The terminal strips are now visible on the terminal PCB. The control PCB may be left hanging while wiring is done. If desired, the control PCB may be disconnected from the cable and set aside while wiring. 7. Guide a four-conductor, shielded cable or four wires in conduit through the top conduit hub of the detector junction box. To make wiring more convenient, use wire colors that correspond to the detector wire colors: red, white, green, and black. NOTE: Consult RKI Instruments, Inc. for cable lengths longer than 200 feet. 8. Connect the detector leads to the terminal block in the detector junction box. 9. Secure the detector junction box s cover to the junction box. 10. Guide the other end of the four-conductor, shielded cable or four wires in conduit through the bottom conduit hub of the M2 junction box. 11. To gain access to a plug-in terminal strip for wiring, pull it out of its socket by grasping the wall between two terminal positions with needle nose pliers and pulling. Be careful not to exert too much force on the wall to avoid damage to the terminal strip. The detector terminal strip and the alarm 1 relay terminal strip may be removed by grasping them with your fingers if the adjacent terminal strips have been removed. WARNING: If the M2 is installed in a hazardous location, use appropriately rated conduit, conduit fittings, and appropriate construction technique that complies with the local electrical code. In addition, use appropriately rated conduit, conduit fittings, and appropriate construction technique to maintain the NEMA 4 environmental rating of the junction box and avoid water entering the junction box at the conduit hubs. 12. Pull out the detector terminal strip and connect the four wires to the terminal strip as follows (see Figure 6). Connect the wire corresponding to the detector s red wire to the LEL R terminal. Connect the wire corresponding to the detector s white wire to the LEL W terminal. Connect the wire corresponding to the detector s green wire to the LEL G terminal RK-04 M2 Transmitter Operator s Manual

17 Connect the wire corresponding to the detector s black wire to the LEL B terminal. CAUTION: If shielded cable is used, leave the cable shield s drain wire disconnected and insulated at the detector junction box. You will connect the opposite end of the cable s drain wire to the M2 junction box s chassis (earth) ground. Cable Shield Detector Terminal Strip PW R/SIG LEL R S S + R W G B A B C A B C R W G B - S + R S 485 L E L P W R/S IG C NC NO C NC NO C NC NO FAIL ALARM 2 ALARM 1 Black Green White Red M2 J-Box Black Green White Red Detector J-Box Combustible Gas Detector Calibration Adapter/Splash Guard Figure 6: Wiring the Detector to the M2 13. Reinstall the detector terminal strip into its socket. 14. If shielded cable is used between the detector junction box and the M2 junction box, connect the cable s drain wire to an available chassis (earth) ground at the M2 junction box. Do not connect the shield drain wire at the detector junction box. 15. Guide multi conductor shielded cable or cables or wires in conduit through the top conduit hub of the M2 junction box. The number of cables or wires needed will RK-04 M2 Transmitter Operator s Manual 12

18 depend on whether the M2 is wired to a gas monitoring controller or just to power, whether any relays are used, and whether the Modbus output is used. NOTE: If the M2 is being wired to a PLC or DCS device, see Appendix B: PLC and DCS Device Wiring on page 48, then continue with step 8. Use the following recommendations to determine how to wire the M2: If Modbus connections will not be used and only the PWR/SIG connections will be used, use a two or three conductor shielded cable or two or three wires in conduit for connections to the power/signal terminal strip depending on whether or not the signal (S) terminal is used. The S terminal has a 4-20 ma output, but if you do not need to monitor this signal and do not connect to the S terminal to access this signal, the M2 will still function completely. Table 3: Wire Size for PWR/SIG Connections Max Distance to Controller w/18 Gauge Wire Max Distance to Controller w/16 Gauge Wire Max Distance to Controller w/14 Gauge Wire 2,500 ft. 5,000 ft. 8,000 ft. If the PWR/SIG connections and one or more relays are used, route the connections to the M2 in conduit. Use shielded cable in the conduit for the PWR/ SIG connections and unshielded cable or individual wires for the relay connections. Make sure any wire or cable used for relay wiring is appropriately rated for the power that it will carry. CAUTION: If shielded cable is used for the PWR/SIG connections, leave the cable shield s drain wire insulated and disconnected at the M2 junction box. You will connect the opposite end of the cable s drain wire at the controller or device. If the M2 will be wired into a Modbus network, see Chapter 8: RS-485 Modbus Output on page RK-04 M2 Transmitter Operator s Manual

19 RKI Controller Terminals See Figure 7 below for field wiring connections to the M2. Alarm Device Cable Shield Power (24 VDC) mAIn (S) S PWR/SIG C NC NO FAIL Fail Alarm Device (24 VDC) - See Detector Wiring R W G B LEL C NC NO ALARM 1 Alarm 1 Alarm Device See Modbus Wiring A B C RS 485 C NC NO ALARM 2 Typical Alarm Wiring Shown Alarm 2 Alarm Device Figure 7: Wiring the M2 Junction Box to a Controller and Alarm Devices 16. Re-install the control PCB (and ribbon cable if necessary). Be sure the ribbon cable is routed down below the control PCB so it will not be damaged by the cover when it is screwed back on. 17. Secure the M2 junction box cover to the junction box. 18. Make controller, device, and relay connections as appropriate. If shielded cable is used for the PWR/SIG connections, connect the cable shield s drain wire to an available chassis ground at the gas monitoring controller, recording device, or programmable controller. Start Up Introducing Incoming Power 1. Complete the installation procedures described earlier in this manual. 2. Verify that all wiring connections are correct and secure. 3. Turn on the incoming power. 4. If necessary, turn on the controller or other monitoring device that is connected to the M2. 5. The LCD display will indicate the firmware version when the M2 is first powered up and will then count down a one minute warm-up period before normal operation begins. During normal operation, the display will indicate the target gas and current gas reading. Verify that the display is indicating the target gas and current gas reading after the warm-up period is complete and normal operation begins. METHANE 0 %LEL RK-04 M2 Transmitter Operator s Manual 14

20 NOTE: Allow the M2 s detector to warm up for 15 minutes before you continue with the next section, Adjusting the Fresh Air Reading. Adjusting the Fresh Air Reading When the M2 is shipped from RKI Instruments, Inc., it is factory calibrated. If a full calibration is desired at startup, see Calibration on page 32. Verify that the M2 is in a fresh air environment (environment known to be free of combustible or toxic gas vapors and of normal oxygen content, 20.9%). CAUTION: If you suspect the presence of combustible gas in the monitoring environment, use the calibration kit and the zero air calibration cylinder to introduce fresh air to the detector and verify an accurate fresh air setting. See the Calibration on page 32 for instructions on how to use a zero air cylinder when performing a fresh air adjustment. Non-Intrusive Fresh Air Signal Adjustment If the M2 is installed in a classified area and non-intrusive zero adjustment is required, follow the instructions below, but do not remove the junction box cover. Use the magnetic wand accessory to actuate the magnetic switches instead of pushing the control switch buttons. To actuate a magnetic switch and perform the same operation as pressing a control switch button, touch the magnet in the end of the magnetic wand to the M2 s glass cover directly over the magnetic switch you wish to actuate. Touching the glass and removing the wand is the same as pressing and releasing a button. Touching the glass and keeping the wand in place is the same as pressing and holding a button. WARNING: The M2 is not an active gas monitoring device during the fresh air adjustment procedure. The 4-20 ma output signal will freeze at 3.5 ma and all relays will remain in their non-alarm state while the M2 is in Calibration Mode. The output signal will not indicate current readings and the relays will not resume operating normally until the M2 is in normal operation again. NOTE: While in the calibration program, if there is no switch activity for the calibration time-out period the unit will return to normal operation. The factory set time-out is 15 minutes. If you want a different time-out period, see Viewing & Changing M2 Parameters on page 22 for instructions to change the calibration time-out. 1. While in normal operation, press and hold the UP/YES button for 5 seconds to enter Calibration Mode. Release the button when the following screen appears. Calib? YES/NO 2. Press and release the UP/YES button to continue. The display will indicate the target gas and CAL Mode for a few seconds before showing FreshAir Adjust?. 3. Press and release the UP/YES button. ENTER will alternate with FreshAir on the top display line and the current gas reading will be on the bottom display line RK-04 M2 Transmitter Operator s Manual

21 4. Press and release the ENTER button. The M2 will perform a zero operation and the display will indicate SPAN w/cal Gas?. 5. Press and release the DOWN/NO button. The display will indicate Leaving CAL Mode and the M2 will return to normal operation RK-04 M2 Transmitter Operator s Manual 16

22 Chapter 4: Operation Overview This chapter describes the M2 in normal operation. This chapter also describes the M2 in alarm 1, alarm 2, and fail conditions and suggests responses to these conditions. Normal Operation Normal operation is defined as follows: The start-up procedure is complete. The M2 is not indicating an alarm 1, alarm 2, or fail condition. The M2 is not in Calibration, Configuration, or Gas Type modes. During normal operation, the M2 simultaneously displays the current gas reading, unit of measure, and target gas. METHANE 0 %LEL Information Screen The Information Screen displays the M2 s operating voltage and firmware and hardware information. To display the Information Screen, do the following: 1. Press and hold the DOWN/NO button for 3 seconds. The Information Screen will appear. 24.2V v5.0l 2A 2. Continue holding the DOWN/NO button to keep the Information Screen on the display. The top line indicates the operating voltage that is connected to the M2. The second line indicates the firmware that is running, version 5.0 in this example, and the M2 s hardware version, version 2A in this example. This information may be useful if you need to contact the factory with questions about the M2. 3. Release the DOWN/NO button when you are done viewing the Information Screen. The display will return to the normal operation screen within a couple of seconds RK-04 M2 Transmitter Operator s Manual

23 4-20 ma Signal Output Operation Alarm Indications The output at the S terminal of the power/signal terminal strip is a 4-20 ma signal that corresponds to the detection range of the M2. During normal operation, this signal tracks the gas concentration on the LCD. There are several circumstances where the signal output will not track the display reading but will behave as follows: When the M2 is in its warm-up period, the signal output will be fixed at 3.5 ma (zero). When the M2 s gas type is changed, the M2 will enter Configuration Mode for you to verify the parameter settings. When you exit Configuration Mode, the display will indicate NEEDS CALIBRATION and will continue to indicate this until Calibration Mode is entered and a calibration is performed. In this situation, the signal output will be fixed at 3.5 ma from the time Gas Type Mode is entered until the M2 is calibrated and returns to normal operation. If you enter Calibration Mode, Configuration Mode, Gas Type Mode, or Modbus Mode, the signal output will be fixed at 3.5 ma until the M2 returns to normal operation. If the M2 s input power decreases below 18.5 volts so that the M2 is in a low power alarm, the signal output is fixed below 2.4 ma until the low power alarm is cleared. If the M2 goes into a fail condition, after a 30 second delay, the signal output is fixed below 2.4 ma until the fail alarm is cleared. NOTE: The M2 includes alarm on and alarm off delay settings for alarm 1 and alarm 2. The alarm indications described in this section operate according to the factory set alarm settings. See Table 5 on page 23 for all the factory settings. Table 4: Visual and Audible Alarm Indications Condition Cause Visual Indication(s) Alarm 1 1 Alarm 2 1 Increasing gas reading at or above the alarm 1 setpoint Increasing gas reading at or above the alarm 2 setpoint A1 LED is on Gas reading alternates with ALARM-1 message A2 LED is on Gas reading alternates with ALARM-2 message Fail Disconnected or misconnected detector wiring Display reading at -10% of full scale or lower Defective components F LED is on FAIL message replaces gas reading NOTE: There is a 30 second delay on the fail condition RK-04 M2 Transmitter Operator s Manual 18

24 Table 4: Visual and Audible Alarm Indications Condition Cause Visual Indication(s) Low Power DC power source less than 18.5 volts. F LED is on LowPower message and actual voltage of incoming DC power * 1 If the M2 is in both an alarm 1 and an alarm 2 condition, both alarm LEDs are on and the display alternates between the gas reading and the ALMS 1&2 message. NOTE: You can select normally energized (N. EN) or normally de-energized (N. DE- EN) alarm 1 and alarm 2 relay settings in Configuration Mode. The following sections describe the standard factory setting for these relays which is N. DE-EN. The fail relay is factory set as N. EN and is not user-adjustable. Alarm 1 Condition Alarm 1 Condition Indications When the gas reading reaches the alarm 1 setpoint, the M2 senses an alarm 1 condition. The M2 alerts you to an alarm 1 condition as follows: The A1 LED turns on. The gas reading alternates with the ALARM-1 message. The alarm 1 relay energizes. Responding to an Alarm 1 Condition 1. Follow your established procedure for a low level combustible gas condition. 2. After the gas reading falls below the alarm 1 setpoint, press the ENTER button to reset the alarm 1 circuit. Resetting the alarm 1 circuit turns off the A1 LED, resets the LCD, and de-energizes the alarm 1 relay. NOTE: If the ENTER button is pressed while the M2 is in an alarm 1 condition, the A1 LED will flash but all other indications will remain unchanged. You cannot de-energize the alarm 1 relay until the gas reading falls below the alarm 1 setpoint. Alarm 2 Condition Alarm 2 Condition Indications When the gas reading reaches the alarm 2 setpoint, the M2 senses an alarm 2 condition. The M2 alerts you to an alarm 2 condition as follows: The A2 LED turns on. The gas reading alternates with the ALARM-2 message. The alarm 2 relay energizes RK-04 M2 Transmitter Operator s Manual

25 NOTE: If the M2 is in both an alarm 1 and alarm 2 condition, both the A1 and A2 LEDs will be on, the gas reading will alternate with the ALMS 1&2 message, and both alarm relays will energize. Responding to an Alarm 2 Condition 1. Follow your established procedure for a high level combustible gas condition. 2. After the gas reading falls below the alarm 2 setpoint, press the ENTER button to reset the alarm circuit. Resetting the alarm circuit turns off the A2 light, resets the LCD, and de-energizes the alarm 2 relay. NOTE: If the ENTER button is pressed while the M2 is in an alarm 2 condition, the A2 LED will flash but all other indications will remain unchanged. Fail Condition You cannot de-energize the alarm 2 relay until the gas reading falls below the alarm 2 setpoint. Fail Condition Indications The M2 indicates a fail condition for any of the following: The detector wiring is disconnected or incorrectly connected. The display reading is -10% of full scale or lower. When the M2 senses a fail condition, it alerts you as follows: The F LED turns on. The gas reading is replaced by the FAIL message. The fail relay de-energizes. NOTE: The fail alarm has a 30 second delay. Responding to a Fail Condition 1. Verify that the detector wiring is correctly and securely connected. Low Power Alarm Low Power Alarm Indications The M2 senses a low power condition when the DC power source is 18.5 volts or less. WARNING: While in a low power condition, the M2 is not an active gas monitor. When the M2 senses a low power condition, it alerts you as follows: The F LED turns on. The message LowPower is indicated on the top line of the LCD and the input voltage is displayed on the bottom line of the LCD. The fail relay de-energizes RK-04 M2 Transmitter Operator s Manual 20

26 NOTE: The low power alarm cannot be cleared using the ENTER button. When the voltage increases to 19.0 volts, the low power alarm is cleared and the M2 will begin its warm-up sequence. Responding to a Low Power Condition 1. Determine and correct the cause of the low power condition. 2. When the input power increases above 19.0 volts, the M2 will begin its warm-up sequence. 3. Verify that the M2 enters normal operation after its warm-up sequence. If necessary, perform a fresh air adjustment. See Adjusting the Fresh Air Reading on page RK-04 M2 Transmitter Operator s Manual

27 Chapter 5: Configuration Mode Overview This chapter describes how to view and change M2 parameters using Configuration Mode. It is accessed using the program buttons. Configuration Mode includes a 5-minute time-out feature. If you do not press a control button for 5 minutes, the M2 automatically returns to normal operation. NOTE: If the M2 returns to normal operation because of a time-out, it enters a warmup period just as it does when it is first turned on. If you are installing a new M2, it has been setup at the factory. Use Configuration Mode only if you want to change the M2 s setup. If you want to change the detector type see Chapter 6: Gas Type Mode on page 25. Viewing & Changing M2 Parameters 1. While in normal operation, simultaneously press and hold the UP/YES and ENTER buttons for 5 seconds to enter Configuration Mode. Release the buttons when the following screen appears. Enter Config? 2. If you want to exit Configuration Mode, press and release the DOWN/NO button and the M2 will return to normal operation. If you want to continue in Configuration Mode, press and release the UP/YES button. The target gas and the full scale will be displayed for a few seconds before the first adjustable parameter, the alarm 1 setpoint, is displayed. 3. If you want to change the currently displayed parameter, use the UP/YES and DOWN/NO buttons to adjust it to the desired setting, then press ENTER to continue to the next parameter. If the currently displayed parameter is OK, press the ENTER button to proceed to the next parameter. Table 5 lists the M2 parameters you can set. Table 5 also lists the factory set value for each parameter RK-04 M2 Transmitter Operator s Manual 22

28 Table 5: Configuration Parameters Parameter (Factory Set Value) ALARM-1 (level) (10% LEL) ALARM-1 (activation) (Increase) ALARM-1 (relay action) (N. DE-EN) ALARM-1 (relay reset) (LATCH) A1 OnDy (alarm 1 on delay) (1 secs) A1 OffDy (alarm 1 off delay) (0 sec.) ALARM-2 (level) (50% LEL) ALARM-2 (activation) (Increase) ALARM-2 (relay action) (N. DE-EN) ALARM-2 (relay reset) (LATCH) A2 OnDy (alarm 2 on delay) (1 secs) A2 OffDy (alarm 2 off delay) (0 sec.) Description The gas reading at which the M2 initiates an alarm 1 condition. Indicates if the alarm 1 circuit is activated by gas readings increasing (Increase) or decreasing (Decrease) to the ALARM-1 Level. If set as N. DE-EN, the alarm 1 relay is de-energized in normal operation and energizes when an alarm 1 condition is initiated. If set as N. EN, the alarm 1 relay is energized in normal operation and de-energizes when an alarm 1 condition is initiated. If set as LATCH, you must press the ENTER button to reset the alarm 1 circuit after the alarm 1 condition passes. If set as SELF-RST, the M2 automatically resets the alarm 1 circuit after the alarm 1 condition passes. The amount of time the M2 delays activation of the alarm 1 circuit once an alarm 1 condition is initiated. It can be set in 1 second increments from 0-60 seconds, in 1 minute increments from 1-15 minutes, and in 15 minute increments from minutes. The amount of time the M2 delays turning off the alarm 1 circuit once an alarm 1 condition passes. This parameter appears only if the alarm 1 relay reset setting is set to SELF-RST. It can be set in 1 second increments from 0-60 seconds, in 1 minute increments from 1-15 minutes, and in 15 minute increments from minutes. The gas reading at which the M2 initiates an alarm 2 condition. Indicates if the alarm 2 circuit is activated by gas readings increasing (Increase) or decreasing (Decrease) to the ALARM-1 Level. If set as N. DE-EN, the alarm 2 relay is de-energized in normal operation and energizes when an alarm 2 condition is initiated. If set as N. EN, the alarm 2 relay is energized in normal operation and de-energizes when an alarm 2 condition is initiated. If set as LATCH, you must press the ENTER button to reset the alarm 2 circuit after the alarm 2 condition passes. If set as SELF-RST, the M2 automatically resets the alarm 2 circuit after the alarm 2 condition passes. The amount of time the M2 delays activation of the alarm 2 circuit once an alarm 2 condition is initiated. It can be set in 1 second increments from 0-60 seconds, in 1 minute increments from 1-15 minutes, and in 15 minute increments from minutes. The amount of time the M2 delays turning off the alarm 2 circuit once an alarm 2 condition passes. This parameter appears only if the alarm 2 relay reset setting is set to SELF-RST. It can be set in 1 second increments from 0-60 seconds, in 1 minute increments from 1-15 minutes, and in 15 minute increments from minutes RK-04 M2 Transmitter Operator s Manual

29 Table 5: Configuration Parameters (Continued) ZeroSupp (2% LEL) FILTER (5 secs) CAL Time (15 mins) Auto Zero (Enabled) Parameter (Factory Set Value) Description The zero suppression feature helps prevent jumpy readings near the fresh air reading. For example, if the zero suppression is 2.0% LEL, the M2 will display a reading of 0% LEL for gas readings from -2% LEL to 2% LEL. It is settable from 0 to 6% of the detection range. The filter feature helps smooth out jumpy or noisy signals from the detector. You can set the filter from 0 seconds to 60 seconds in 5 seconds increments. The displayed gas reading is the average reading over the previous time period defined by the filter setting. So if the filter is set to 5 seconds, the displayed gas reading is the average over the past 5 seconds. The calibration time-out sets the amount of time after the last button push while in Calibration Mode that the M2 will wait before returning to normal operation. If the calibration time-out is set to 15 mins, then M2 will return to normal operation automatically 15 minutes after the last button push. If set to Enabled, the M2 s firmware will monitor the zero (fresh air) reading and make automatic zero adjustments under precisely specified conditions if it determines that a reading change is due to normal sensor drift. If set to Disabled, the Auto Zero function is turned off. 4. When you have scrolled through all the adjustable parameters, SAVE IT? YES/NO appears on the display. 5. If you do not wish to save the adjustments and want to exit Configuration Mode, press and release the DOWN/NO button. The DO OVER? YES/NO message will display. Press and release the DOWN/NO button. The ABORT? YES/NO message will display. Press the UP/YES button to return to normal operation. If you wish to change some of the adjustments made, press and release the DOWN/ NO button. The DO OVER? YES/NO message will display. Press and release the UP/ YES button. The Re-do Config message will display and the M2 will return to the first adjustable parameter. Go back to step 3 and continue. If you wish to save the adjustments made, press and release the UP/YES button. Config Saved is indicated on the display for a few seconds and the M2 returns to normal operation RK-04 M2 Transmitter Operator s Manual 24

30 Chapter 6: Gas Type Mode Overview This chapter describes how to use Gas Type Mode to select the M2 s gas type. The gas type determines the target gas and detection range. CAUTION: The target gas is factory set and does not normally need to be changed. The standard setting for the RK-04 is methane, but it may be different depending on the calibration. Gas Type Mode includes a 5-minute time-out feature. If you do not press a button for 5 minutes, the M2 automatically returns to normal operation. NOTE: If the M2 enters normal operation because of a program time-out, it enters a warm-up period just as it does when it is first turned on. Selecting the Gas Type 1. While in normal operation or during the warm-up sequence, press and hold the UP/ YES and DOWN/NO buttons for five seconds. Release them when the following screen appears. Select GasType? 2. If you want to exit Gas Type Mode, press and release the DOWN/NO button. The display will indicate NO CHANGE and the M2 will return to normal operation. If you want to continue in Gas Type Mode, press and release the UP/YES button. The top display line will indicate GasType? and the bottom display line will indicate the target gas choice. 3. Use the UP/YES or DOWN/NO button to scroll through the choices of target gas. Table 6 below lists the choices of target gas for the M2. Table 6: Gas Types Gas Type Choices Detection Range HC ibutane PROPANE HEXANE HYDROGEN METHANE 0-100% LEL 0-100% LEL 0-100% LEL 0-100% LEL 0-100% LEL 0-100% Volume RK-04 M2 Transmitter Operator s Manual

31 Table 6: Gas Types METHANE CO2 CO2 CO2 CO2 CO2 NH3 NH3 Gas Type Choices Detection Range 0-100% LEL 0-5,000 ppm 0-2,000 ppm 0-100% volume % volume % volume % volume % volume 4. When the desired target gas is on the display, press and release the ENTER button. The display will ask SAVE IT? YES/NO. 5. To discard the gas type change, press and release the DOWN/NO button. The display will ask DO OVER? YES/NO. Press the DOWN/NO button. The display will ask ABORT? YES/NO. Press the UP/YES button. The M2 will return to normal operation without changing the gas type. To save the gas type, press and release the UP/YES button. The display will indicate Gas Type Updated, the display will indicate the target gas and the detection range for a few seconds, and then the M2 will enter Configuration Mode automatically so that the parameter settings in Configuration Mode can be verified or changed. 6. While in Configuration Mode press and release the ENTER button to accept the displayed parameter setting and move to the next one. Use the UP/YES and DOWN/ NO buttons to adjust a setting. See Chapter 5: Configuration Mode on page 22 for a complete description of Configuration Mode. 7. When you have reviewed and accepted the last item in Configuration Mode by pressing the ENTER button, display will ask SAVE IT? YES/NO. 8. To save the configuration settings, press and release the UP/YES button.the display will indicate Config Saved and the M2 will begin its warm-up sequence. To discard the settings and review them again, press the DOWN/NO button. The display will ask DO OVER? YES/NO. Press the UP/YES button and the display will indicate Re-do Config, then display the target gas and the detection range for a few seconds before returning to Configuration Mode. Repeat steps 6-8 until the settings are as desired. 9. After the M2 completes its warm-up sequence, the display will indicate CAL NEEDED. Since the gas type has been changed, a successful calibration must be performed before the M2 can enter normal operation. 10. Press and release the UP/YES button to enter Calibration Mode. Normally, you must hold the UP/YES button for 5 seconds to enter Calibration Mode, but since a calibration is required, only a momentary push is needed to enter Calibration Mode after changing the gas type. 11. See Calibration on page 32 for calibration instructions RK-04 M2 Transmitter Operator s Manual 26